Packaging method and apparatus



' J. BRUCE 2,864,212

PACKAGING METHOD AND APPARATUS Dec.- 16, 1958 17 Sheeiis-Sheet 1 Filed May 31, 1955 INVENVTOR. JOHN K. BRUCE Q BY f W M4M ATTOQNEYS Dec.'16, 1958 1K. BRUCE mcmcmc mz'mon mo APPARATUS l7 Sheets-Sheet 3 Filed May 31, 1955 '8 IN VEN TOR.

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J. K. BRUCE PACKAGING moo mo APPARATUS 17 Shets-Sheet 4 INVENTOR. JOHN K. BRUCE A TTOQNE V S Dec. 16, 1958 J. K. BRUCE PACKAGING METHOD AND APPARATU$ Filed Ma 31, 1955 mvsuron. Jun/v K. anuc z PACKAGING mom m0 APPARATUS 17 Sheets-Sheet 6 Filed May 31, 1955 12 INVENTOR. JOHN K. VBRUCE FIG. /0. BY M,M Mj

ATTORNEYS Dec. 16, 1958 JQ-K. BRUCE PACKAGING METHOD AND APPARATUS Filed May 31. 1955 FIG. /3.

17 Sheets-Sheet 8 INVENTORV JOHN x. 00005 BY mm M422 ATTORNEYS 16, 1958 J. K. BRUCE PACKAGING METHOD AND APPARATUS 1'7 Sheets-Sheet 9 Filed May 31, 1955 FIG. /4.

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L w h Dec. 16, 1958 J. K. BRUCE mmmc uz'mon mm APPARATUS 17 Sheets-Sheet 17 Filed May 31, 1955 INVENTOR. JOHN K. BRUCE PACKAGING METHOD AND APPARATUS John K. Bruce, South Pasadena, Calif., assignor to Bruce Engineering Corporation, Pasadena, Calif., a corporation of California This invention relates to a process for packaging containers and to apparatus suitable for performing the process in a continuous operation so as to meet volume requirements of commercial packaging operations. This application is a continuation in part of my co-pending application Serial No. 361,723, filed June 15, 1953, now abandoned.

The invention is directed to the fabrication of packages of the type described in United States Patent No. 2,667,- 995, issued February 2, 1954, to Thomas H. Davis and myself. The package illustrated and claimed in this patent comprises a plurality of beaded containers as exemplified by conventional tin cans, and which, for the purpose of this description, will be assumed to be six in number, arranged about a core and held in bead to head coplanar relation about the core by a tensioned band. The band forms a package wall. The package is characterized by the absence of bottom and top closures, the structural independence of the core and tensioned band, and, in preferred embodiment, actual spatial separation of core and band. By constructing the core to be confined between and to engage opposite end beads of each of the cans in the package group, the package is structurally stable and may be suspended from the core in spite of the independence of core and wall member. Although the present invention, is described with relation to a six container pack, it is to be understood that a greater or lesser number of containers may be packaged in like manner.

The core, in one embodiment, comprises a longitudinal vane which may be composed of relatively stifr' cardboard and which extends longitudinally between two adjoining rows of three cans each. The longitudinal vane is notched at spaced and vertically aligned points in its upper and lower edges to receive transverse vanes. The transverse vanes may be in the form of relatively narrow strips, each strip being symmetrically disposed in one of the respective notches in the longitudinal vane to extend between adjoining cans of each row and to engage respectively the top abutting and bottom abutting beads of such adjoining cans.

The longitudinal vane may be shorter than the can rows, i. e., shorter than three times the container diameter, and the transverse vanes may be shorter than twice the diameter of each container. As a consequence the extremities of the core may be spaced inwardly from the Wall member to avoid any engagement between the two.

Alternatively, the core may comprise an integral element, say of cast plastic, of substantially the same configuration as defined above, including a longitudinal vane and transverse vanes extending outwardly at spaced and transversely aligned points from both faces of the longitudinal vane. I

The package is unique in that the containers themselves are not only supported and confined thereby, but form an integral and necessary partof the package providing structural unity and stability to the otherwise struc- "ice turally unrelated core and resilient wall band. As a consequence of this interrelation, the containers are in efiect packaged simultaneously with the fabrication of the package, and fabrication and packaging must be carried out in the same process. The containers are a necessary component of the package before the package can assume any reality as such.

Because the containers are, in fact, part of the package and impart structural unity to the otherwise disassociated elements, a special method of assembly or fabrication of the package is required. The conventional procedure of forming containers, cartons, or carrying forms, and thereafter inserting suitable numbers of containers therein, cannot be followed in a package of the type described.

The invention contemplates a process of fabricating a package of the type having a plurality of beaded containers confined about a core by a resilient encircling band, the core having longitudinal and transveres vanes confined between and engaging the opposite end beads of each container. The process comprises the sequentially carried out steps of inserting a container into each core compartment formed by the longitudinal and transverse vane members and with the several containers in cm planar head to head abutting relationship so that the container beads lie respectively above and below the upper and lower edges of the core. A resilient wall band is enlarged to encompass an area larger than the area of the container group and is placed around the exterior of the container group. The band is then caused to contract about the container group in frictional binding relation to the portion of the wall surface of the corner containers of the group.

The resilient wall band may be of the type that is stretchable within an elastic limit for applying to the container group and thereafter allowed to contract about the containers. Alternatively, the band may be of a type which is contracted by .an applied stimulus such as heat. Under this circumstance it is applied to the container group in the expanded form and thereafter contracted under the influence of such stimulus.

In a preferred embodiment of the method as'described, the core is supported in vertical orientation, and in this orientation it is caused to move past container feed means adapted to simultaneously position containers on opposite sides of the central vane and with the container beads overhanging and underhanging the upper and lower edges of the core, i. e., the upper and lower edges of the central vane, the upper edges of the upper transverse vanes and the lower edges of the lower transverse vanes.

If an articulated core is employed, the above described method is modified to include the initially carried out step of assembling such a core. A preferred method of assembling an articulated core is described in detail with relation to the drawing.

The method as described above can be carried out by hand in exactly the sequence and manner set forth. However, such manual fabrication is obviously economically impractical for commercial application, and semiautomatic or automatic machinery is definitely required. I have developed apparatus for packaging containers in the manner set forth and adapted to automatically carry out the process steps outlined above. Whereas, the application in its preferred form is completely automatic, commencing with the assembly of the core and carrying through to the final insertion of suspension means in the core, any portion of the apparatus is replaceable by manual operation or by non-automatic machine operation.

The invention therefore contemplates apparatus for fabricating a package of the type described comprising a conveyor, means for supporting the core in an upright position on the conveyor, serially arranged means for feeding containers onto the conveyor simultaneously on opposite sides of the core, means for urging a group composed of the correct number of containers inwardly and into bead to bead abutting relation about the central and transverse vane members of the core, means for supporting the resilient band to encompass an area larger than the area of the container group and of similar shape, and means for positioning the means for supporting the resilient band to allow the band to restrict about the container group.

When employing an articulated core, the apparatus includes means for assembling such core and specifically for engaging the transverse vanes in the appropriate manner with the longitudinal vane. Preferably the core is assembled on the conveyor in the desired vertical orientation.

Complete apparatus for package assembly in accordance with the method of the invention comprises a conveyor, a core assembler, container injector, film feeder (the term film being used with reference to the band), a band applicator, and a bailer. One form of apparatus of this general type is described in my co-pending application Serial Number 361,723. The present apparatus differs structurally from that described in said co-pending application, although the ultimate formation and objective remain unchanged. These differences will become apparent from the detailed description and drawings.

The method and apparatus of the invention will be more clearly understood with reference to the following detailed description thereof taken in conjunction with the accompanying drawing:

Fig. 1 is a perspective view of a package according to the invention;

Fig. 2 is a perspective view of a core as embodied in the package of Fig. 1;

Fig. 3 is a perspective view of a complete embodiment of apparatus in accordance with the invention;

Fig. 4 is a schematic perspective view of the drive mechanism of the apparatus of Fig. 3;

Fig. 5 is a graph of conveyor veocity as a function of time;

Fig. 6 is a plan view of the core assembly and container feed means portion of the apparatus taken along line 6-6 of Fig. 3;

Fig. 7 is a front elevation of the core assembly and container feed means portion of the apparatus of Fig. 3;

Fig. 8 is a rear perspective view partly broken away of the core assembly portion of the apparatus of Fig. 3;

Fig. 9 is a fragmentary vertical transverse section taken along line 9-9 of Fig. 6;

Fig. 10 is a transverse vertical section taken along line 10 10 of Fig. 6;

Fig. 11 is a fragmentary vertical section taken on line 11-11 of Fig. 6;

Fig. 12 is a fragmentary longitudinal section taken along line 12-12 of Fig. 11;

Fig. 13 is a transverse vertical section of a film feed and band applicator portion of the apparatus of Fig. 3 viewed in the direction of conveyor travel;

Fig. 14 is a perspective view of the film feed unit, isolated from the band applicator apparatus;

Fig. 15 is a fragmentary rear elevation taken along line 15-15 of Fig. 13;

Fig. 16 is a fragmentary rear elevation taken along line 16-16 of Fig. 13;

Fig. 17 is a plan section taken on line 17-17 of Fig. 15;

Fig. 18 is an enlarged fragmentary rear elevation partly broken away of the band applicator driving means;

Fig. 19 is a fragmentary plan section taken along line 19-19 of Fig. 18;

Fig. 20 is a sectional elevation taken along line 20-20 of Fig. 16;

Fig. 21 is a front elevation, partly broken away, of the applicator and film feed portion of the appar t ta en along line 21-21 of Fig. 13; a

Fig. 22 is an elevation, partly in section, taken along line 22-22 of Fig. 21;

Fig. 23 is a sectional view taken along line 23-23 of Fi 22;

Figs. 24 through 27 are schematic representations of the positions of the band applicator during one revolution of the driving means; and

Figs. 28 through 31 are schematic representations of the applicator finger positions at successive stages of the band application process.

The package shown in plan view in Fig. 1 comprises a core 40 shown separately in perspective in Fig. 2. The

core comprises a central vane 40A and transverse vanes 40B, 40C, 40D, 40E. The four transverse vanes are arranged in vertically aligned pairs and each extends symmetrically from opposite sides of the central vane, i. e., extends approximately equidistant from opposite faces of the central vane. The core may be articulated with the transverse vanes residing in appropriately positioned notches in the upper and lower edges of the central vane. No bond is required between the vanes inasmuch as they are held in position by the containers in the final package. Alternatively, the core may be produced as an integral unit in the illustrated shape, as for example from plastic. Plastic can be cast or molded for this purpose.

The core 40 in effect forms six container receiving compartments, three on either side of the central vane 40A, each container being partially confined between the central vane and one or more of the transverse vanes. Containers 41 are shown as thus positioned in the package of Fig. 1 and forming a rectangular group comprising two parallel rows of three containers each. The core member is sized so as to be confined between the opposite end beads of the containers 41 and so that the upper and lower edges of the core engage against the respective end beads of each of the containers.

A band of film 42 encircles the group of containers under tension serving to hold them in snug bead to bead engagement with the core as described. In preferred practice, as illustrated in Fig. l, the central vane is shorter than the major axis of the rectangular group of containers and the transverse vanes are shorter than the minor axis of the rectangular group of containers, resulting in spatial separation between the extremities of the core and the band 42. A bail 43 engages under the upper transverse vanes on respectively opposite sides of the longitudinal vane. The package itself is described and discussed in considerable detail in the co-pending application referred to above.

The invention is described and illustrated as utilized to fabricate a six unit package. Packages of lesser or greater number of containers can be fabricated with equal facility by the described method and with the illustrated apparatus with suitable modification thereof to accommodate the desired number of containers. Continued reference to a six container package does not imply any limitation to such effect.

The complete embodiment of automatic continuously operating apparatus for carrying out the package process herein described is illustrated in the perspective view of Fig. 3. The apparatus is too extensive to show all of its details in this figure, and the detailed description thereof is taken in relation to succeeding figures of the drawing. The apparatus is logically divided into functional sections and is illustrated and described herein in such manner.

As illustrated in Fig. 3, the basic units in the preferred embodiment are a core assembler 44, a container injector 45, film applicator units 46 and 46A and bailers 47, 47A. These units are arranged in association with a conveyor system 48 which receives a supply of beaded containers 41 from a source not shown. The containers are delivered to the container injector by means of auxiliary conveyors 49 and 49A arranged on either side of the core assembler. For better understanding of the over-all operation of the machine a brief description of the function of each unit follows.

The core assembler supplies in sequence lower transverse vanes D and 40E, longitudinal vane 40A, and upper transverse vanes 40B and 40C to the conveyor. The conveyor carries the assembled core 40 to container injector which laterally injects three containers into the core on either side of the longitudinal vane. The containers are held in position within the core and. against paired bosses 50, A provided at spaced. intervals along conveyor 48 by a series of adjacent paired magnets 51, 51A, which are shown in detail. in Figs. 10 and 12. The containers, held in the core by the magnetic means, are moved into position beneath a band applicator turret 52 forming part of the film applicator 46.. The applicator including the turret cuts a band from a tubular film length, expands the band to an area greater than that of the grouped containers, applies the band around the containers and core, and allows the band to contract about the containers. The operation of the film applicator 46A is identical with that of film applicator 46, the travel of the conveyor being controlled to position alternate filled cores beneath each of the applicator turrets. The banded containers are conveyed to the bailers 48 and 48A, and wire handles 43 are installed in respectively alternate packages by each of the bailers.

The conveyor is housed in a substantially Urshaped base 55 and is synchronously driven with respect to the rest of the units by linkage means best described with reference to Fig. 4. A single source supplies power for the operation of the entire apparatus of the preferred embodiment with the exception of the auxiliary conveyors 49, 49A. As illustrated in Fig. 4 a prime mover 56 is linked by a conventional chain, link belt 57 and sprockets 58, 59 to a transverse shaft 60 carrying a first wheel and pitman drive system 61 and a conventional sprocket 62 (broken lines). The pitman arm is provided with a gear rack 63 which drives a spur gear 64. The spur gear is fixed to a shaft 65 which carries aunidirectional clutch 66. The drive unit drives conveyor chain link belts 67, 68 and imparts to the conveyor intermittent unidirectional motion of changing velocity as pictured in the graph of Fig. 5 and described in detail in the above-mentioned copending application.

The chain sprocket 62 fastened to shaft 60 drives a second transverse shaft 70 to which a second wheel and pitman drive system 71 is fastened. The second wheel and pitman drive system actuates film applicator 46A. Sprockets 75, 76 and chain link belt 77 connect the second wheel and pitman drive system to a film feed drive 80. Film applicator 46is actuated by a third wheel and pitman drive system 81 deriving its motion from a third transverse shaft 82, a sprocket 83, a chain link belt 84 driven by a sprocket 85 fixed to the shaft --of the film feed drive. The core assembler responds to the revolutions of a disk 86 to which the assembler mechanism is connected by a crank 87 and a pivoted lever arm 88. The d sk is revolved by a conventional chain and sprocket system 89 that couples the disk to shaft 82 of the first film applicator.

A pair of star wheels 90, 91 of the container injector are driven by respective pairs of bevel gears 92, 93 and 94, 95 which are in turn driven by a shaft 96coupled by a sprocket 97 and chain link belt 98 to a driven shaft 99 of the conveyor system. This. positively linked drive system powered from a single prime mover eliminates the need for intricate electrical and mechanical timing and interlocking systems which would otherwise be necessary to synchron'ze the separate procedures of the various units. As will become apparent, synchronization is essential to operation of the system.

The conveyor itself is composed of a plurality of narrow metal strips 101 (see Fig. 12), each of which is fastened by L-shaped clips 102, 103 at its outer ends to links 104, 105 (Fig. 10) of chain link belts 67, 68 which are driven from the described elliptical drive. At uniform intervals along the, conveyor thus formed bosses are fastened to the strips in spaced pairs with bosses 50, 50A of each pair being spaced in the direction of the movement of the conveyor by a distance equal to the diameter of the containers. The bosses are slotted in the direction of and transversely to conveyor travel to accommodate respectively the longitudinal and transverse vanes of the core. the vanes when inserted will be spaced from the upper surface of the conveyor by a distance not less than the depth of the bead on the container. 7

The core assembler, which supplies the cores to the conveyor belt, is illustrated in detail in Figs. 6 through 9. The core assembler comprises a housingl10 situated at the upstream end of the conveyor housing between the pair of auxiliary container conveyors. Since the embodimerit of Fig. 3 has duplicate units to increase package output, the core assembler has paired components of identical function. The lower and upper transverse vanes of the core are inserted into the slotted bosses of the conveyor respectively from a pair of supply magazines 111, 112 mounted to the core assembler housing near its upstream end and a similar pair of supply magazines 113, 114 mounted at the downstream end of the core assembler housing. The upstream pair of magazines are designed each to supply the two lower transverse vanes for a core and are mounted with their vane delivery ends only a short distance from the surface of the conveyor, allowing clearance for the slotted bosses. The downstream supply magazines are spaced upwardly from the conveyor to perform their function of delivering the upper transverse vanes of the core.

The longitudinal vanes are supplied from a pair of horizontal tracks 115, 116 comprised of pairs of upwardly and inwardly opening angle iron strips 117, 117A and 118, 118A, respectively, which support the longitudinal vanes in a vertical position. The longitudinal vanes are fed into insertion position. by means of an impelling frame 119 positioned at the supplying end of each stack of longitudinal vanes. To each impelling frame is fixed a pair of cables 120, 120A which run over pulleys 121,

121A mounted respectively to the track frame and the track angle iron'strips and fasten at their bottom ends to a counterweight 122. The pulleys and cables are illustrated in Fig. 9. Spring-loaded ratchet dogs 123 on either side of the frame engage a back face 124 of the last longitudinal vane in the supply stack and directly impart a loading force against the stack.

The lower and upper transverse vanes are fed from the supply magazines into the slotted bosses and the longitudinal vane notches respectively by pivoted ejector arms (not shown) substantially identical to ejector arms 125, 125A, 1258, 125C associated with supply magazines 113, 114 (see Fig. 7). The longitudinal vanes are impelled intoplace from each supply magazine by a vertical ejector plate carried by a vertical rack 131 linked to the plate by means of fiat head machine screws 132 guided in a groove (not shown) in a vertical support plate 133. Motion is imparted to the vertical rack by a gear 134 which derives its motion in turn from a horizontal rack 135 mounted on a reciprocating drive plate 136. The drive plate is supported in a vertical position between a plurality of rollers 137, 137A, 1373, etc., mounted to a rear housing wall 138 shown in Figs. 8 and 9 and a roller 139 pivotally mounted to the upper end of an L-shaped crank 140 pivotally connected to the upper end of lever arm 88 (see Fig. 4). Roller 139 engages in a slot 141 in the drive plate. The ejector arms of Fig. 7 are given their pivoting motion by a chain of intermeshed segmental gears 142, 142A, which are driven by spur gears 143, 143A meshed with horizontal gear racks 144, 144A fastened to the drive plate. The drive plate is reciprocated by the crank and lever system which is linked at its lower end to the chain driven wheel 86' whose power source was described in conjunction with the description of Fig. 4. Thus, for every cycle of mt The depth of the slots is such that 

